Note: Descriptions are shown in the official language in which they were submitted.
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METHOD AND SYSTEMS TO CONTROL MUNICIPAL SOLID WASTE
DENSITY AND HIGHER HEATING VALUE FOR IMPROVED WASTE-TO-ENERGY
BOILER OPERATION
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. 119(e)
from U.S. Provisional Patent Application No. 60/876,581 filed on
December 22, 2006, the subject matter of which is herein
incorporated by reference.
Field of the Invention
[0002] The present invention relates to an improved Municipal
Waste Combustion system and method. Particularly, the
embodiments of the present invention improve upon known
municipal waste combustors (MWCs) by incorporating means for
accurately calculating the moisture content.of the input waste
to be combusted in the MWC.
BACKGROUND OF THE INVENTION
[0003] In the Waste-to-Energy (WTE) industry, the heating value
of municipal solid waste (MSW) is generally considered to be an
unmeasurable and uncontrollable variable. Local weather,
particularly rainfall, dramatically impacts MSW heating value,
and in turn, the processing capacity and operating
characteristics of waste-to-energy boilers. This variable is
the largest distinction between mass burn waste-to-energy and
other forms of combustion-based steam generation. The ability
to measure effectively changes in MSW heating value would
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enhance boiler operation by providing a critical input to boiler
combustion controls that has been previously unavailable. In
addition, the ability to control the moisture content of the MSW
to a relatively constant value, by regulating the addition of
water or liquid waste, would further enhance the boiler
operation, as well as improve the predictability of waste
processing rates, by making constant a previously uncontrolled
variable.
[0004] It is known to measure moisture content in liquid waste,
such as sludge. For example, United States Patent 6,553,924
issued to Beaumont, et al. relates to a system and method for
injecting and co-combusting sludge in a municipal waste
combustor, where the moisture content of the sludge is monitored
and controlled prior to combustion, but these techniques are
generally not applicable to solid waste management and
combustion because it is technically challenging to accurately
and efficiently measure the moisture content in large volumes of
solid waste in hostile conditions near the MWC furnace.
SUMMARY OF THE INVENTION
[0005] In response to these and other needs, embodiments of the
present invention enable direct measuring of the density of the
MSW fuel as an indicator of moisture content using nuclear
radiation density meters positioned to monitor input waste prior
to combustion. In one embodiment, a typical nuclear moisture-
density meter contains sealed radioactive materials, typically
cesium and a combination of americium mixed with beryllium
powder. The radioactive materials emit nuclear radiation that a
detector can count when the radiation passes through the MSW.
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This count can be translated to a density value. The density
value can then be used to infer a moisture content measurement
for the MSW.
[0006] In one aspect of the invention a method for combustion
control in solid waste incineration systems is provided. The
method includes the steps of feeding solid waste into an input
system; determining the moisture content of the solid waste
prior to the solid waste entering a combustion chamber;
adjusting the combustion process in response to the determined
moisture content; and passing the solid waste into the
combustion chamber.
[0007] In another aspect of the invention a solid waste
combustion system is provided. The system includes a municipal
waste combustor, the municipal waste combustor including a
combustion chamber. The system also includes a waste input
system configured to feed solid waste into the combustion
chamber. Also included in the system is a moisture sensor
adapted to determine moisture content of the solid waste prior
to the waste entering the combustion chamber. Finally, the
system includes a controller in communication with the moisture
sensor, wherein said controller receives information from the
moisture sensor and regulates the operation of the municipal
waste combustor and/or the waste input system in response to
said information.
[0008] In embodiments of the present invention, the moisture
content measurement for the MSW can be used as a feed forward to
the MWC to adjust the combustion process accordingly.
[0009] Because radiation-based measurement is a statistically
random process, multiple density sensors can be configured in
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series to measure the waste density several times. Then a final
density measure can be determined, for example, from an average
reading from the multiple density sensors, with the moisture
content estimate produced using the average measured density.
[0010] In one embodiment, the density sensor instrument(s) would
be situated to read fuel density in a plane passing through the
MSW feed hopper just above a ram table where the MSW is forced
into a combustion chamber. In this way, the MSW could be
measured just prior to introduction into the combustion chamber
in the MWC.
[0011] Alternatively, multiple measuring points in this plane
would ensure a fair representation of the MSW condition.
[0012] A smoothed density reading would then be used to
characterize the boiler control parameters (such as air
distribution and control system gains) to improve combustion
control and enhance boiler stability. The MSW density reading
would also be used to control liquid injection rates to maintain
a relatively constant MSW heating value. The controlled heating
value would be at the lower end of the normal range, enabling
the boilers to operate close to their grate limit on a
continuous basis, and thereby maximize the MSW tons processed,
regardless of the variations in MSW composition and heating
value.
[0013] In one embodiment, the output of this density measurement
may be correlated to changes in MSW heating value and used as a
feedforward input to the combustion controls.
[0014] In another embodiment, the moisture/density measurements
may be used to control a water injection process to control the
MSW heating value.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A more complete understanding of the present invention
and advantages thereof may be acquired by referring to the
following description taken in conjunction with the accompanying
drawings in which like reference numbers indicate like features,
and wherein:
FIG. 1 depicts an improved Municipal Waste Combustion
(MWC) system in accordance with embodiments of the
present invention is presented;
FIG. 2 provides a schematic representation in the form of
a longitudinal section through a combustion system of an
MWC; and
FIG. 3 provides a flow chart of a method for controlling
the heating value of municipal solid waste(MSW) in an MWC.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] As depicted in the figures and as described herein, the
embodiments of the present invention provide an improved
Municipal Waste Combustion system and method. Specifically, the
embodiments of the present invention adapt known municipal waste
combustors (MWCs) by incorporating means for accurately
calculating the moisture content of the input waste to be
combusted in the MWC. Through better measurement of the waste
moisture contents, combustion in the MWC can be better
controlled to achieve desired results, including reduced
emissions and greater combustion efficiency.
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[0017] Changes in moisture content can alter MSW tons processed
as much as 10%, however, waste-to-energy boilers rarely operate
at their grate capacity limit. The effect of this idea would be
to maintain the boiler close to its grate limit at all times,
which should result in an increased MSW throughput of about 5%.
[0018] Reduction in fuel variance would also improve consistency
of operation resulting in more net power output by minimizing
low swings caused by MSW composition and heating value changes.
[0019] Turning now to FIG. 1, an improved MWC system 100 in
accordance with embodiments of the present invention is
presented. The MWC system 100 includes a MWC 100 for combusting
Municipal Solid Waste (MSW) 110 and a waste input system 120 for
supplying the MSW 110 to the MWC 100. Various types of the MWC
100 are known and include, for example, moving grate combustors,
rotary-kilns in which waste is transported through the furnace
by moving teeth mounted on a central rotating shaft, and
fluidized bed in which a strong airflow is forced through a sand
bed. Likewise, depending on the type of MWC 110 a variety of
kinds of waste input system 120 may be used.
[0020] Generally, MSW 110 is burned in the MSC 100 and the
energy from the combustion is used to heat water to create high
pressure steam. Combustion air from duct 150 and other
variables may be adjusted to optimize the combustion process.
[0021] One or more moisture sensor 130 is located at a point
generally prior to the furnace of the MWC 100 to measure the
moisture content of the MSW 110. The moisture sensor 130 may be
in the form of a density sensor, such as a nuclear radiation
density meter, which indirectly estimates moisture content of
the MSW 110. Other types of moisture sensor 130 may include an
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air humidity sensor located in the vicinity of the MSW 110
combustion. As another alternative, moisture sensor 130 may
include a height measurement of the MSW 100 to estimate density
and thereby estimate moisture content. Moisture sensor 130 may
include a single sensor or multiple sensors of the same type
that take measurements at different points in the MSW input
stream. Moisture sensor 130 may also include a combination of
different types of sensors, such as a nuclear radiation density
meter and an air humidity sensor.
[0022] Continuing with the improved MWC system 100 in FIG. 1, a
controller 140 receives status information from and regulates
the operation of the MWC 100 and the waste input system 120. In
known systems, the type of information received by the
controller 140 typically includes feedback status information
from the MWC 100 about combustion process, such as the furnace
temperature(s),.the measured levels of various output pollutants
such as carbon monoxide, and other measured levels such as the
amount of elemental oxygen within the furnace. In addition to
this conventional information, information from moisture sensor
130 is provided to the controller 140 and used to adjust input
flow from the waste input system 120 and the air flow from duct
150. Furthermore, the controller 140 further receives feed-
forward information about the status of the waste input system
120. This information typically relates to the amount and
timing of municipal waste introduced into the MWC 100.
[0023] These systems are explained in more detail below by an
example of the arrangement in FIG. 2, which is a schematic
representation in the form of a longitudinal section through a
combustion system 200 of an MWC. While a particular combustion
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system 200 is depicted in FIG. 2 and described below, it should
be appreciated that the principles of the present invention may
be adapted to a variety of incineration system to achieve
desired optimal MSW processing rates.
[0024] As can be seen in FIG. 2, the combustion system 200 in
this exemplary embodiment has a feed hopper 210 followed by a
feed chute 220 for supplying the fuel to a feed table 235, on
which feed rams 240 that can be moved to and fro are provided to
convey the fuel arriving from the feed chute 220 onto a
combustion grate 250 on which combustion of the fuel takes place.
Whether the grate is sloping or is horizontally arranged and
which principle is applied is immaterial.
[0025] A density meter 230 is located to read fuel density in a
plane passing through the feed chute 220 just above the ram
table 235. Preferably, multiple measuring points in the same
plane may be used to ensure a fair representation of the MSW
condition.
[0026] Still referring to FIG. 2, a controller (such as
controller 140 from FIG. 1) receives status information from a
variety of monitored functions and regulates the operation of
the MWC 200 and the MSW 290 input. The reading from density
meter 230 would also be used by the controller to control liquid
(e.g., water or liquid waste) injection rates, such that liquid
would be added to comparatively dry waste to maintain a
relatively constant MSW heating value. The controlled heating
value would be at the lower end of the normal range, enabling
the boilers to operate close to their grate limit on a
continuous basis, and thereby maximize the MSW tons processed,
regardless of the variations in MSW composition and heating
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value. As a compliment to liquid injection, automatic
regulation of other process parameters including excess air
ratio, feed water temperature and combustion air preheat
temperature may be incorporated in the control strategy to
permit process operation at a relatively constant firing rate.
The target firing rate would be optimized for the specific
financial goal of the facility in which the invention is
deployed.
[0027] In the representative embodiment shown in FIG. 2, below
the combustion grate 250 is arranged a device, denoted in its
totality by 260, that supplies primary combustion air and that
can consist of several chambers 261 to 265 into which primary
combustion air is introduced via a duct 270 by means of a fan
275. Through the arrangement of the chambers 261 to 265, the
combustion grate is divided into several undergrate air zones so
that the primary combustion air can be adjusted to different
settings according to the requirements on the combustion grate.
[0028] Above the combustion grate 250 is a furnace 280 which
leads into a flue gas pass 285 which is followed by components
that are not shown, such as a heat recovery boiler and a flue
gas cleaning system. The rear area of the furnace 280 is
delimited by a roof 288, a rear wall 283 and side walls 284.
Combustion of the fuel denoted by 290 takes place on the front
part of the combustion grate 250 above which the flue gas pass
285 is located. Most of the primary combustion air is
introduced into this area via the chambers 261, 262 and 263. On
the rear area of the combustion grate 250 there is only
predominantly burnt-out fuel, or bottom ash, and primary
combustion air is introduced into this area via the chambers 264
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and.265 primarily for cooling purposes and to facilitate
residual burnout of the bottom ash.
[0029] The burnt-out fuel then falls into a discharger 295 at
the end of the combustion grate 250. Optionally, nozzles 271
and 272 are provided in the area of the flue gas pass 285 to
supply secondary combustion gas to the rising flue gas, thereby
mixing the flue gas flow and facilitating post combustion of the
combustible portion remaining in the flue gas.
[0030] In certain embodiments of the invention, the improved MWC
system described herein may be combined with other known
combustion techniques for reducing unwanted emissions such as
those described in co-pending and commonly assigned U.S. Patent
Application Nos. 11/529,292, filed September 29, 2006, and
11/905,809, filed October 4, 2007 which are incorporated herein
by reference in their entirety.
[0031] FIG. 3 provides a flow chart of a method 300 for
controlling the heating value of MSW in an MWC. In step S310,
the MSW is fed into the input system of an MWC. External
factors such as weather, waste-types, and transport conditions
can effect the heating value of the MSW, and in turn, the
processing capacity and operating characteristics of waste-to-
energy boilers. Thus, in step S320 the moisture content of the
input waste is monitored prior to the waste entering the
combustion chamber of the MWC.
[0032] In one embodiment, monitoring step S320 is accomplished
using one or more nuclear radiation density meters to directly
monitoring waste density to estimate moisture content. A
typical nuclear moisture-density meter contains sealed
radioactive materials, typically cesium and a combination of
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americium mixed with beryllium powder. The radioactive
materials emit nuclear radiation that a detector can count when
the radiation passes through the MSW. This count can be
translated to a density value. The density value can then be
used to infer a moisture content measurement for the MSW.
[0033] In step S330, the combustion process is adjusted in
response to the monitored reading step S320. As discussed with
respect to the previous figures, process variables may be
adjusted to maintain a relatively constant MSW heating value. In
certain embodiments, the controlled heating value would be at
the lower end of the normal range. In step S340 the MSW is
forced into the combustion chamber and incinerated, creating
heat used for high pressure steam or other energy sources.
[0034] While the invention has been described with reference to
an exemplary embodiments various additions, deletions,
substitutions, or other modifications may be made without
departing from the spirit or scope of the invention. Accordingly,
the invention is not to be considered as limited by the
foregoing description, but is only limited by the scope of the
appended claims.
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